Usulan Perbaikan Sistem Perawatan Mesin Digester Menggunakan Metode Failure Mode Effect Analysis (FMEA) dan Reliability Centered Maintenance (RCM) pada PKS Pagar Merbau

Abstract

PKS Pagar Merbau is one of the factories owned by PTPN II that produces CPO. This study was conducted on the factory's machine with the highest frequency of breakdowns, the digester machine. The current maintenance policy is only corrective maintenance, where repairs are made only when a machine is broken. This results in sudden machine failures, decreased reliability, and significant downtime, leading to time and cost losses due to production delays. The study aims to propose improvements to the maintenance system by implementing preventive maintenance on the digester machine using the Reliability Centered Maintenance and Failure Mode Effect Analysis methods. The expected outcome is to prevent machine failures, thus improving machine reliability. The critical components of the digester machine, identified as the ones with the highest failure frequency, are the bearing, v-belt, and electric motor. Five preventive maintenance policies were proposed: scheduled restoration tasks for worn bearings, scheduled discard tasks for cracked bearings and the v-belt, and scheduled restoration and discard tasks for noisy and failed electric motors, respectively. The implementation of preventive maintenance using the RCM method resulted in a replacement schedule for the digester's critical components: bearings every 67.45 days, v-belts every 67.68 days, and electric motors every 40.53 days.